Prediction of polycrystalline materials texture evolution in machining via Viscoplastic Self-Consistent modeling

The crystallographic orientation or anisotropy is one of the main microstructural attributes strongly affecting the mechanical properties of materials. It is also an influential parameter to be considered during the manufacturing process especially for ultra-precision machining since it affects part quality, tool performance, and process productivity through material properties. In this study, a prediction toolset constituted of a Viscoplastic Self-Consistent model and machining process mechanics model is used to predict the texture evolution on the machined surface. The VPSC (Viscoplastic Self-Consistent) methodology which uses the mechanisms of slip and twinning that are active in single crystals of arbitrary symmetry was used. For this, an analytical model for the process mechanics is derived to understand the forces and stresses generated by the cutting tool at each workpiece point, then the strain and strain rate to capture the rate at which the material is deforming and finally the crystallographic orientations under various machining conditions. Experiments were performed on the orthogonal cutting of aluminum alloy AA-7075-T651 and the texture results were compared to model predictions.     

An Approach to Theoretical Modeling and Simulation of Face Milling Forces

A new approach to theoretical modeling and simulation of face milling forces is presented. The present approach is based on a predictive machining theory in which machining characteristic factors in continuous cutting with a single-point cutting tool can be predicted from the workpiece material properties, tool geometry, and cutting conditions. The action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and the milling forces are predicted from input data of workpiece material properties, cutter parameters and tooth geometry, cutting condition, cutter and workpiece vibration structure parameters, and types of milling. A predictive force model for face milling is developed using this approach. In the model, the workpiece material properties are considered as functions of strain, strain rate, and temperature. The ratio of cutter tooth engagement over milling is taken into account for the determination of temperature in the cutting region. Cutter runout is included in the modeling for the chip load. The relative displacement between the cutter and workpiece due to the cutter and workpiece vibration is also included in the modeling to consider the effect on the undeformed chip thickness. A milling force simulation system has been developed using the model, and face milling experimental tests have been conducted to verify the simulation system. It is shown that the simulation results agree well with experimental results.     

Experimental investigation,intelligent modeling and multi-characteristics optimization of dry WEDM process of Al–SiC metal matrix composite

Dry wire electrical discharge machining (WEDM) is an environmentally friendly modification of the oil WEDM process in which liquid dielectric is replaced by a gaseous medium. In the present work, parametric analysis has been fulfilled while dry WEDM of Al–SiC metal matrix composite. Experiments were designed and conducted based on L₂₇ Taguchi's orthogonal array to study the effect of pulse on time, pulse off time, gap voltage, discharge current, wire tension and wire feed on cutting velocity (CV) and surface roughness (SR). Firstly, a series of exploratory experiments has been conducted to identify appropriate gas and wire material based on the values of cutting velocity. After selection of best gas and best wire, they were used for later stage of experiments. Analysis of variances (ANOVA) has been performed to identify significant factors. In order to correlate relationship between process inputs and responses, an adaptive neuro-fuzzy inference system (ANFIS) has been employed to predict the process characteristics based on experimental observation. At the end, an artificial bee colony (ABC) algorithm has been associated with ANFIS models to maximize CV and minimize SR, simultaneously. Then the optimal solutions that obtained through ANFIS-ABC technique have been compared with numbers of confirmatory experiments. Results indicated that oxygen gas and brass wire guarantee superior cutting velocity. Also, according to ANOVA, pulse on time and discharge current were found to have significant effect on CV and SR. In modeling of CV and SR by ANFIS, it was resulted that the proposed method has superiority in prediction of them in the ranges of factors beyond the training condition. Also, association of ANFIS with ABC can find the optimal combination of process parameters accurately according to the confirmatory experiments.     

Measurement of tool internal temperatures in the tool–chip contact region by embedded micro thin film thermocouples

Sensors capable of providing fast and reliable feedback signals for monitoring and control of existing and emerging machining processes are an important research topic, that has quickly gained academic and industrial interest in recent years. Generally, high-precision machining processes are very sensitive to variation in local machining conditions at the tool–workpiece interface and lack a thorough understanding of fundamental thermomechanical phenomena. Existing sensors to monitor the machining conditions are not suitable for robust in-process control as they are either destructively embedded and/or do not possess the necessary spatial and temporal resolution to monitor local tool internal temperatures during machining at the cutting tip/edge effectively. This paper presents a novel approach for assessing transient tool internal temperature fields in the close vicinity of less than 300 μm of the tool cutting edge. A revised array layout of 10 micro thin film micro thermocouples, fabricated using adapted semiconductor microfabrication methods, has been embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts by means of a modified diffusion bonding technique. Scanning electron microscopy was used to examine material interactions at the bonding interface and to determine optimal bonding parameters. Sensor performance was statically and dynamically characterized. They show good linearity, sensitivity and very fast response time. Initial machining tests on aluminum alloys are described herein. The tests have been performed to demonstrate the functionality and reliability of tool embedded thin film sensors, and are part of a feasibility study with the ultimate goal of applying the instrumented insert in hard machining operations. The microsensor array was used for the acquisition of tool internal temperature profiles very close to the cutting tip. The influence of varying cutting parameters on transient tool internal temperature profiles was measured and discussed. With further study, the described instrumented cutting inserts could provide more valuable insight into the process physics and could improve various aspects of machining processes, e.g. reliability, tool life, and workpiece quality.     

AFM probe based nano mechanical scribing of soda-lime glass

In recent years, demands for miniature components have increased due to their reduced size, weight and energy consumption. In particular, brittle materials such as glass can provide high stiffness, hardness, corrosion resistance and high-temperature strength for various biomedical and high-temperature applications. In this study, cutting properties and the effects of machining parameters on the ductile cutting of soda-lime glass are investigated through the nano-scale scratching process. In order to understand the fundamentals of the material removal mechanism at the atomic scale, such as machined surface quality, cutting forces and the apparent friction, theoretical investigation along with experimental study are needed. Scribing tests have been performed using a single crystal diamond atomic force microscope (AFM) probe as the scratching tool, in order to find the cutting mechanism of soda-lime glass in the nano-scale. The extended lateral force calibration method is proposed to acquire accurate lateral forces. The experimental thrust and cutting forces are obtained and apparent friction coefficients are deduced. The effects of feed rates and the ploughing to shearing transition of soda-lime glass have been investigated.     

双氧水强化微电解法模拟降解苯酚的研究

苯酚是最简单的有机模型化合物,对其进行降解试验有助于了解微电解作用机理,为含酚废水的治理提供试验方法及工艺参数。试验得出最佳工艺为:当进水pH=3,H2O2加入量为0.1％,反应时间10 min时,出水TOC去除率>90％。发现进水中H2O2的加入对微电解法具有明显的强化作用,对作用机理进行了探讨。     

Application of FEM simulation of chip formation to stability analysis in orthogonal cutting process

Models for chatter prediction in machining often use a mechanistic force model that calculate the force as the product of a material dependent cutting constant and chip area. However, in reality, the forces are the result of complex interaction between the tool and the chip, and are affected by many factors. The effects of these complex, and often nonlinear, factors on the machining dynamics may only be included in chatter prediction if the chip formation process is simulated concurrently with simulation of the machining dynamics. In this paper, finite element simulation of the chip formation process is combined with simulation of chatter dynamics and the inter-relationship between the chip formation process and the chatter phenomenon is investigated. Mesh adaptation technique is used to simulate the chip formation within an FEM elastoplastic analysis with dynamic effects and frictional contact. The combined modeling predicts the occurrence of process damping at low cutting speeds, which other models are generally unable to predict.     

岩溶流域地下水TOC输出及影响因素分析:以重庆丰都雪玉洞地下河流域为例

2014年8月至2015年9月通过野外在线监测获取岩溶流域连续、高精度的气象、地下水TOC和水文地球化学等数据,利用主成分回归模型探讨流域地下水TOC在不同时间尺度上的输出及影响因素.结果表明在季节时间尺度上,气温和地下水电导率(Sp C)夏季高,冬季低,p H则相反;TOC和浊度冬、夏季高,春、秋季低;地下水TOC和水文地球化学指标对降雨表现出明显的响应过程,但地下水TOC对不同降雨强度的响应时间和过程有明显差异,整体来说,TOC在降雨过程中表现出上升的趋势,而暴雨过后受稀释效应影响呈现下降趋势.主成分回归分析发现降雨、流量和浊度对TOC有正向促进作用,而气温和p H对TOC有负向的影响.     

Experimental investigation of the machining induced residual stress tensor under mechanical loading

Residual stress induced by machining is complex and difficult to predict, since it involves mechanical loads, temperature gradients or phase transformation in the generation mechanism. In this work, an experiment with a statistical design for the residual stress tensor was performed to investigate the residual stress profile on a machined surface. In order to understand the generation mechanism of residual stress in machining, three variables and workpiece materials were carefully selected to focus on the mechanical loads and avoid the temperature gradients and phase transformation on the machined surface. The mechanical loads considered here included the chip formation force at the primary shear zone and the plowing force at the tool tip–workpiece contact. Depths of cut and rake angles were selected to alter the chip formation force, and the tool tip radius was designed to emphasize the plowing effect. The workpiece material was aluminum 3003. The experimental results showed that the chip formation force provides basic shapes of the residual stress profile for a machined surface. It decides the depth of the peak residual stress below the surface. However, the plowing force was the dominating effect on the surface residual stress, causing high stresses on the surface. The plowing force can shift the surface stress from tensile to compressive. Additionally, the measured stress tensor proved that in-plane shear stress exists for the machined surface.     

Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel

Residual stress profile in a component is often considered as the critical characteristic as it directly affects the fatigue life of a machined component. This work presents an analytical model for the prediction of residual stresses in orthogonal machining of AISI4340 steel. The novelty of the model lies in the physics-based approach focusing on the nature of contact stresses in various machining zones and the effect of machining temperature. The model incorporates: (i) stresses in three contact regions viz. shear, tool-nose-work piece and tool flank and machined surface, (ii) machining temperature, (iii) strain, strain rate and temperature dependent work material properties, (iv) plastic stresses evaluation by two algorithms, S-J and hybrid, (v) relaxation procedure and (iv) cutting conditions. The model benchmarking shows (86–88%) agreement between the experimental and predicted residual stresses in the X- and Y-directions. On the machined surface, the tensile residual stresses decrease with an increase the edge radius and increase with an increase the cutting speed. However, below the surface, the compressive residual stresses increase with an increase the depth of cut. Further, it is observed that the proposed model with hybrid algorithm gives better results at a lower feed rate, whereas with the S-J algorithm, at a higher feed rate.     

Experimental study using the dilution incubation method to assess water biostability

Water biostability is of particular concern to water supply as a major limiting factor for heterotrophic bacterial growth in water distribution systems. This study focused on bacterial growth dynamics in the series dilution of water samples with TOC（total organic carbon） values determined beforehand. The results showed that the specific growth rate of Pseudomonas fluorescens P17 varied dramatically and irregularly with TOC value when TOC concentrations were low enough during the initial periods of incubation under given conditions. According to this relationship between bacterial growth rate and TOC, a dilution incubation method was designed for the study of water biostability. With the method under a given condition, a turning-point TOC value was found at a relatively fixed point in the curve between bacterial growth rate and TOC of water sample, and the variation of growth rate had different characteristics below the turning-point TOC value relative to that over this value. A turning-point TOC value similarly existed in all experiments not only with tap water, but also with acetate and mixed solutions. And in the dilution incubation method study, the affections were analyzed by condition factors such as inoculum amount,incubation time and nature of the organic carbon source. In very low organic carbon water environments, the variation characteristics of bacterial growth rate will be useful to further understand the meaning of water biostability.     

Process capability study of laser assisted micro milling of a hard-to-machine material

Laser assisted micro milling (LAMM) is capable of generating three-dimensional micro scale features in hard-to-machine materials. This paper compares the process capability of LAMM with conventional micro milling of a hardened tool steel. In particular, the potential advantages of LAMM over micro milling with respect to cutting forces, tool wear, material removal rate, burr formation and surface roughness are investigated when micro milling hardened A2 tool steel (62 HRC). The results show that LAMM has significant advantages over micro milling, especially in terms of cutting forces, material removal rate and tool wear. The average reduction in the resultant cutting force is found to be up to 69% with laser assist. In addition, tool wear is found to be substantially less with laser assist even when the material removal rates are increased by a factor of six over the tool manufacturer recommended cutting conditions.     

A Study on Torch Path Planning in Laser Cutting Processes Part 1: Calculation of Heat Flow in Contour Laser Beam Cutting

Conductive heat transfer in contour laser beam cutting is analyzed by using a transient, two-dimensional finite difference model, and the result is combined with a simple analytic model. From the calculation results, the correlation is derived between workpiece temperature and opening angles at a corner in contour cutting. As a result, a modified analytic solution is developed to predict if excessive workpiece heating occurs for given cutting contours in a nested plate. The main objective is to use the computation results in the optimization of torch path planning to provide fully automated CNC programming software for laser cutting. To efficiently apply the analytic model in torch path planning, the critical temperature that should be avoided during the cutting sequence is considered. This leads to an improvement of the cutting quality in the automatic cutting process.     

矿化垃圾生物反应床堵塞问题探讨

针对矿化垃圾生物反应床处理渗滤液的堵塞问题,研究并探讨了堵塞原因和堵塞治理、预防措施。结果表明:渗滤液中有机悬浮物在矿化垃圾表层的截留与吸附是造成矿化垃圾反应床堵塞的主要原因之一。在该文试验条件下,二级串联工艺中,第一级反应床的表层总有机碳含量随时间的延长而增加,总有机碳从最初的9.4%提高到发生堵塞时的10.7%;而中部垃圾的总有机碳含量则维持在9.4%～9.5%。第二级反应床表层和中部垃圾的总有机碳分别维持在9.2%～9.5%和9.0%～9.4%,未发生明显变化。通过矿化垃圾累计降解污染物的量,提出了矿化垃圾极限负荷和临界负荷的概念。     

南黄海冷水团海域及西部近岸区表层沉积物中碳、氮、磷的分布特征及其生态学指示意义

基于南黄海西部沉积化学及相关环境因子的调查资料,重点分析和探讨了冷水团海域及近岸区表层沉积物中TOC、TN、TP的分布特征及其生态学指示意义.结果显示,冷水团海域沉积物比近岸区沉积物具有较高的含水率、TOC、TN、TP含量及N/P比.沉积物类型(粒径)、物质来源和沉积环境显著影响着TOC含量,TOC高值主要分布在泥质沉积区.表层沉积物TN与TOC含量在冷水团海域呈显著正相关关系,表明两者的同源性较好,但整个调查海域中TP与TOC、TN无显著相关性,说明其来源较复杂.南黄海冷水团海域和西部近岸浅水区沉积物理化特性之间的显著差异反映了它们受控因素的迥异,冷水团海域沉积物TOC和TN含量受水柱中生物活动的影响较大,上层水体中产生的有机碎屑是其重要的海生物质来源,而浅水区沉积物TN和TP含量受水柱中生物活动的影响相对较小.底层水年平均DO含量对沉积物TOC、TN分布也具有一定影响.     

Basic Approach to a Prediction System for Burr Formation in Face Milling

Geometric parameters and material properties are the two major categories of factors affecting burr formation in the milling process. Geometric parameters such as tool geometry, workpiece geometry, or process condition influence workpiece edge quality at the tool-chip interface. This study identifies a unified criterion to analyze burr formation for different tool engagements. The criterion exploits the exit order of cutting edges of the tool along the workpiece edge, which essentially includes the 3-D nature of the process. The criterion correlates the cutting mechanism and burr formation using the exit order sequence (EOS) as an approximation of chip flow angle. The impact of different possible exit order sequences on burr formation is analyzed. Previously observed phenomena are explained based on the EOS. Also, experiments are done with three different materials (with different ductilities) to analyze the impact of material properties on burr formation for a given EOS. Although burr sizes are different quantitatively with different material, the ranking of burr size for different EOS remained the same. An algorithm for the prediction of burr formation in face milling based on EOS is developed and tested and validated on two different profiles of an automotive part.     

水平潜流人工湿地有机物去除模型研究

以总有机碳(TOC)做为模型参数,建立了1个水平潜流人工湿地有机物去除机理模型.通过对试验数据的拟合得到模型中的未知参数,再对模型进行验证.结果表明,模型预测值与实测值的吻合较好.种植花叶芦竹的水平潜流人工湿地和空白湿地对生活污水中总有机碳的去除率分别为92%和91%,去除的主要途径为生物降解作用,生物降解量占进水总有机碳的84%.植物对总有机碳去除有促进作用,但影响不大.     

经口摄入土壤多溴联苯醚生物可给性变化及影响因素的体外消化模拟

误食土壤是污染物(如多溴联苯醚)人体(主要是儿童)暴露的重要途径,人体消化道内污染物吸收的生物可给性是针对此种暴露方式进行定量风险评估的有效途径之一.本研究采用体外消化实验模拟3种不同有机碳含量的天然土壤中典型多溴联苯醚(BDE-28、BDE-47、BDE-99和BDE-153)在胃和小肠消化液中的释放,验证部分消化释放的多溴联苯醚因消化残留固相表面的再吸附造成低估实际生物可给性,并通过不同水土比的拟合计算予以校正.结果表明,校正后的消化率普遍高于校正前;就不同土样而言,BDE-28、BDE-47、BDE-99和BDE-153在不同初始暴露浓度条件下平均提升比例范围分别为14.3%~42.3%、11.1%~32.1%、4.9%~12.3%和0.0%~7.7%.因此,未经校正的消化率会显著低估PBDEs消化道内的生物可给性,尤其是低溴代组分及PBDEs初始浓度较高或高TOC含量的土样.校正后BDE-28、BDE-47、BDE-99和BDE-153的消化率分别维持在21.9%~54.7%、18.8%~43.1%、13.4%~27.2%和9.3%~19.9%.此外,PBDEs的消化率与其辛醇-水分配系数的对数lg KOW呈显著负相关;而与土壤TOC含量及PBDEs初始暴露浓度的相关性并不显著,尤其是高溴代组分.     

Evaluation of RothC model using four Long Term Fertilizer Experiments in black soils, India

Carbon content in soils changes depending on the land use system, type of management practice and time. There is an increasing concern about the soil quality vis-à-vis organic carbon content in soils due to global warming and enhanced CO₂ concentration in the atmosphere. This has led to estimate carbon stock in soils at global and regional levels. The objective of the present study was to evaluate RothC model to estimate total organic carbon (TOC) changes under four long term fertilizer experimental sites representing sub-humid moist (Sarol and Nabibagh), sub-humid dry (Panjri) and semi-arid (Teligi) climate in India. The plant carbon input rate was calibrated using organic carbon and other soil parameters using RothC. The results showed that RothC could simulate changes in TOC in two contrasting eco-sites for surface soil layers. The root mean square error (RMSE) considered as modelling error ranged from 11.50 to 15.01, 4.70 to 11.60, 2.14 to 6.52 and 1.45 to 13.74 in the surface layers of Sarol, Nabibagh, Panjri, and Teligi sites, respectively. The simulation biases expressed by M (relative error) by Student‘t’ value for all the treatments at these sites were non-significant with two exceptions. Observed trends in TOC consist of an increase for all the four treatments in the sub-humid site of Sarol and Nabibagh; while manures alone or in combination increase TOC appreciably in Teligi and Panjri. TOC remained, however, almost similar over years for the control (no fertilizer or manure) and NPK treatments in all the four sites. Analysis of RothC output data showed that this model could be used as a tool to arrive at different threshold values of rainfall to influence decomposition rate modifier and thus to find out rate of organic carbon sequestration in various bioclimatic systems.     

Abrasive jet machining by means of velocity shear instability in plasma

The material removal within different machining process can be performed in distinct modalities. One of the modality is based on the erosion phenomena. In this paper, theoretical model of abrasive jet machining based on erosion phenomenon is discussed. The material is removed from the surface due to erosion. In abrasive jet machining process, the output parameter is achieved by controlling various input parameters. This paper discusses the effects of various input parameters in abrasive jet machining (AJM) on the material removal rate (as the output parameter). The results presented in the paper are obtained from a theoretical study carried out with the help of mathematical model and computational technique. Theoretical investigation indicates that magnetic field, electric field and inhomogeneity in DC electric field have significant effect on metal removal by abrasive jet machining process.